CLUTCH – CLUTCH UNIT CL–31

CLUTCH UNIT
CLUTCH
TRANSMISSION

COMPONENTS

FLYWHEEL SUB-ASSEMBLY
CL
RELEASE BEARING HUB CLIP

x6

19 (195, 14)

CLUTCH DISC ASSEMBLY

CLUTCH COVER ASSEMBLY

CLUTCH RELEASE BEARING ASSEMBLY

CLUTCH RELEASE FORK SUB-ASSEMBLY

47 (480, 35)
RELEASE FORK SUPPORT
CLUTCH RELEASE FORK BOOT
N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part Clutch spline grease Release hub grease

C132969E01
 CL–32 CLUTCH – CLUTCH UNIT

DISASSEMBLY
1. REMOVE MANUAL TRANSAXLE ASSEMBLY
See page MX-24.
2. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY
(a) Remove the clutch release fork with the clutch
release bearing from the transaxle assembly.

CL 3. REMOVE CLUTCH RELEASE BEARING ASSEMBLY

(a) Remove the release bearing hub clip and clutch
release bearing assembly from the clutch release
fork.

C069774

4. REMOVE RELEASE FORK SUPPORT

(a) Remove the release fork support from the manual
transaxle assembly.
5. REMOVE CLUTCH RELEASE FORK BOOT

C083809

6. REMOVE CLUTCH COVER ASSEMBLY

Matchmarks
(a) Put matchmarks on the clutch cover assembly and
flywheel sub-assembly.
(b) Loosen the 6 bolts one turn at a time until spring
tension is released.
(c) Remove the 6 bolts and pull off the clutch cover
assembly.
NOTICE:
Do not drop the clutch disc assembly.
D008941E02
7. REMOVE CLUTCH DISC ASSEMBLY
NOTICE:
Keep the lining part of the clutch disc assembly, the
pressure plate and surface of the flywheel sub-
assembly away from oil and foreign matter.
INSPECTION
1. INSPECT CLUTCH DISC ASSEMBLY
(a) Using vernier calipers, measure the rivet head
depth.
Minimum rivet depth:
0.3 mm (0.012 in.)
If necessary, replace the clutch disc assembly.

C104164
 CLUTCH – CLUTCH UNIT CL–33

(b) Install the clutch disc assembly to the transaxle

assembly.
NOTICE:
Take care not to insert the clutch disc assembly
in the wrong direction.
(c) Using a dial indicator with a roller instrument,
measure the clutch disc assembly runout.
Maximum runout:
0.8 mm (0.031 in.) CL
If necessary, replace the clutch disc assembly.

Transaxle
Side

C127504E02

2. INSPECT CLUTCH COVER ASSEMBLY

(a) Using vernier calipers, inspect the diaphragm spring
B for depth and width of wear.
A Maximum:
A (Depth):
0.5 mm (0.020 in.)
B (Width):
6.0 mm (0.236 in.)
If necessary, replace the clutch cover assembly.
D025281E01

3. INSPECT FLYWHEEL SUB-ASSEMBLY

(a) Using a dial indicator, measure the flywheel runout.
Maximum runout:
0.1 mm (0.004 in.)
If necessary, replace the flywheel sub-assembly.

C127506

4. INSPECT CLUTCH RELEASE BEARING ASSEMBLY

(a) Check that the bearing moves smoothly without
abnormal resistance by turning the sliding parts of
the bearing (contact surfaces with the clutch cover)
while applying force in the axial direction.
(b) Inspect the bearing for damage or wear. If
necessary, replace the release bearing assembly.

N000414E01
 CL–34 CLUTCH – CLUTCH UNIT

5. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

SST (a) Using a dial indicator with a roller instrument, check
the diaphragm spring tip alignment.
Maximum variation:
0.5 mm (0.020 in.)
If alignment is not as specified, adjust the
diaphragm spring tip alignment with SST.
SST 09333-00013
CL
D008946E01

REASSEMBLY
1. INSTALL CLUTCH DISC ASSEMBLY
SST (a) Insert SST into the clutch disc assembly, then insert
them into the flywheel sub-assembly.
SST 09301-00220
NOTICE:
Take care not to insert the clutch disc assembly
in the wrong direction.

Flywheel
Side

C127508E01

2. REMOVE AND INSTALL CLUTCH COVER

3 7
ASSEMBLY
SST 1 (Temporarily), 4 (a) Align the matchmarks on the clutch cover assembly
with the one on the flywheel sub-assembly.
(b) Following the procedures shown in the illustration,
6 tighten the 6 bolts in order, starting with the bolt
located near the knock pin on the top.
5 Torque: 19 N*m (195 kgf*cm, 14 ft.*lbf)
2 Matchmarks HINT:
C127509E02 • Following the order in the illustration, evenly
tighten the bolts one turn at a time.
• Lightly move SST up and down, and right and left
after checking that the disc is in the center to
tighten the bolts.
SST 09301-00210